Possible N75 valve?

StrayBassist

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Sacramento, California
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98 New Beetle ALH
Well, here we are.

Unfortunately I don't have a VCDS scanner nor can I afford one; though I am looking into VCDS Lite, though there's conflicting information on what cables will work for it and what cables work on Windows 10..

I had 3 instances where I would suddenly be rev limited to about 3K, and low on power, but no MIL. Turning off the car, waiting a minute or so and turning it back on would fix the issue. I only experienced them after driving the car hard - such as merging onto the highway and really revving the engine out. After this, it didn't happen for a long time until my girlfriend started borrowing my car to commute to work while we repair hers, this time finally tripping the P1550 code, rev limiting the car as well as being very low on power, and getting abysmal fuel economy. (I usually go about 65-75 miles before one 'dot' on the NB fuel gauge goes down, now she's gone through a quarter tank in about 70 miles)

She cleared the code to see if it'd come back, and it did - only once - but the limp mode is persistent now.

So far I've inspected the air filter (I replaced it only 6k miles ago so as expected, it's fine.) and the snow screen seems to already have been deleted by the previous owner, so that's fine.

I didn't notice an abnormal amount of buildup in the intake.

I haven't done a proper vacuum test on all of the lines (if anyone knows where I could get a pump to check them, maybe harbor freight?) but visual and tactile inspection seems that the ones I can get to so far are fine.

I was told to try swapping the N75 valve and N18 solenoids, and I did. The car seemed incredibly sluggish, the turbo was far quieter, and although it was quite a struggle to get up to/above 3K in any gear other than 1st and 2nd, I didn't seem to be rev limited. People have told me to try swapping these two, but not what to actually look for - does this confirm a bad N75 solenoid or not..?

The only thing I haven't really inspected yet is the VNT actuator/vanes, though I plan to when I wake up tomorrow morning and will update accordingly. I kind of doubted it'd be a soot buildup issue since I'd driven the car hard a few times before, taking it to a mountain road, and passing or merging on the highway without issue.

Am I just best off buying the KermaTDI Limp Mode kit and replacing everything, or is it most likely my N75? What can I do to further narrow it down?

EDIT: I just recalled an important detail I'd forgotten about it until checking my text history with the girlfriend; the first time the MIL showed up it also apparently threw a code P1161 (Intake Air Temp Sensor open/short to positive) and P1156 (MAP sensor open/short to ground). I hadn't considered it because those codes only came up once, and because of how many people have told me it's unlikely to be the MAF, but that might be worth investigation.. is MAF cleaner safe to use on our cars?
 
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P2B

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An electrical issue with the MAP/IAT sensor (as indicated by the P1156 and P1161 codes) will cause permanent limp mode if detected at key on because the ECU has no way to measure boost pressure.

I would start by checking the wiring harness for the MAP/IAT sensor located on top of the intercooler.
 

Tdijarhead

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Lawrenceville PA
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2003 TDI Jetta Daughters Car, 2001 TDI Beetle, Wife’s car, 2005 Golf TDI Mine, all 5 spds
You’re experiencing “limp mode”, when shutting off the car and restarting restores power. Here is Canadian Grizzly’s diagnosing and fixing low power. Work your way through it.

 

P2B

Top Post Dawg
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2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
You’re experiencing “limp mode”, when shutting off the car and restarting restores power.
the limp mode is persistent now.
Important distinction - if the car goes into limp mode only after driving in a manner that calls for boost, and cycling the ignition temporarily restores power, then you have a boost control issue which can be diagnosed by following the procedure @Tdijarhead linked.

If the car is permanently in limp mode, then the MAP/IAT sensor codes point to sensor wiring as the issue.
 

snakeye

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2003 Jetta and Wagon, GLS 5sp
Depending on the size of your arm you can simply reach behind the engine and press down on the actuator lever to see if it moves freely. That would rule out the turbo.

Also check the brake booster hose where it connects at the vacuum pump. The engine moving during acceleration can cause a leak there which could trigger limp mode.
 

StrayBassist

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Location
Sacramento, California
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98 New Beetle ALH
Alright, everybody, we've come to a consensus.

Following Canadian Grizzly's guide:

MAF sensor... I tried unplugging it and there was zero change in power or throttle response.. turbo was much louder though! When I got the car back in November, I noticed the previous owner had an absolutely raggedy air filter in there, absolutely chock full of dirt - I replaced it, the fuel filter, as well as an oil and filter change all in one go, but it seems damage to the MAF was already done. There were straight-up strands of.. nature, like small twigs in there. Yikes. I replaced it and immediately got a code for MAF short to ground. reseating the connection a few times and it seemed fine. On the way back from the auto parts store, throttle response was way better than I'd ever had with the car, the turbo sounded like it was kicking in way earlier, I was stoked. Until I got onto the freeway, shifted into fourth and kept my foot down while I merged and suddenly I lost all of the newfound power, and was once again rev limited at 3K, struggling to get above 80 MPH. I also got the MAF short to positive connection, so I assume my connector is probably bad.. I was also willing to bet that wasn't the only thing wrong with the car.

I got a cheap vacuum tester from harbor freight and checked the line from the N75 as the guide suggested - my gauge maxed out at 28 inHg, so well within spec. Lines are good!

VNT actuator/vains.. I lifted up the car, crawled under with a light and found the actuator quickly. I first moved it with my hand, about 3/4 inch of play and moves easily. I hit it with some PB Blaster anyways just in case. Couldn't hurt, I figured.

Next up was checking the N75 itself - I had my girlfriend turn on the car while I looked under there and.. huh, the actuator didn't move at all.. the guide said it was supposed to. Giving it a bit of throttle and... nope. Hm..

While I was busy overthinking and worrying about my car, my girlfriend put the pressure gauge in her mouth and confirmed she could suck hard enough to create 27 inHg of vacuum. No, seriously. She put the line to the actuator in her mouth, I looked at the actuator and she uh, applied vaccum... and boom! It moved! So it seems like my N75 solenoid just isn't moving the actuator at all.

At least I think I diagnosed it correctly.. I found a solenoid on RockAuto with the same part number as the one I have with the pre-2000 square plug, and ordered it. Part of me is still very anxious about whether I did everything right (or as right as I can without a VCDS scanner) but I'll keep everyone updated with how it all shakes out for me. If there's any tips in the meantime, do let me know.
 

vwxyzero

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'96 TDI Passat Sedan, '96 TDI Passat Wagon, & Jetta Sedan, '83 Turbodiesel (IDI)
While I was busy overthinking and worrying about my car, my girlfriend put the pressure gauge in her mouth and confirmed she could suck hard enough to create 27 inHg of vacuum. No, seriously. She put the line to the actuator in her mouth, I looked at the actuator and she uh, applied vaccum... and boom! It moved! So it seems like my N75 solenoid just isn't moving the actuator at all.
Good girlfriend, bad N75!
 

Zak99b5

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Albany NY
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2003 Jetta TDI
Use the vac pump on the line that goes to the VNT actuator. See if it starts around 3” and if it hits the stop at 18”.
 

snakeye

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2003 Jetta and Wagon, GLS 5sp
Good girlfriend, bad N75!
27 inHg... She's definitely a keeper.

Another test you can do which I always suggest is to attach a t-fitting to your vacuum gauge and monitor the vacuum on different lines (like N75 to turbo) in real time as you're driving the car. Like that, you know what's actually going on in driving conditions. For instance, the brake booster hose could vibrate and cause a leak which wouldn't manifest itself while testing with the engine off. Still, I think vacuum in and not enough vacuum out pretty much points to a bad N75 valve, so hopefully that fixes your issue!

The N75 vents excess vacuum to the airbox, so it could well have ingested some of the detritus that killed the MAF.
Seems pretty unlikely. That line vents air to the dirty side of the air box, so logically nothing should go into that line, unless the lines were somehow mixed up...
 

P2B

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Toronto & Muskoka, Canada
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That line vents air to the dirty side of the air box, so logically nothing should go into that line, unless the lines were somehow mixed up...
Actually that line sucks air from the clean side in order to vary the vacuum applied to the actuator. Connecting it to the dirty side would be illogical.
 

snakeye

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Actually that line sucks air from the clean side in order to vary the vacuum applied to the actuator. Connecting it to the dirty side would be illogical.
Oh wow my bad. Now that I think of it it's true; that nipple on the air box is right next to the intake pipe. So with the intake in the state that it was in, that's a good guess.
 

StrayBassist

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Sacramento, California
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98 New Beetle ALH
27 inHg... She's definitely a keeper.
Good girlfriend, bad N75!
Heheh, she's pretty amazing. She helps me with my TDI, and I help her with her '86.5 Supra. Believe it or not, the Toyota engine is more of a pain to work on...

I got my N75 in today, hooked everything up, started the car and drove it to the closest highway. First I noticed the turbo spooling up nice and loud, felt like great throttle response and power. While merging onto the highway, I wasn't rev limited and I was able to get up to 80 MPH really easily. I drove on the highway for a bit, got off at the next exit and started driving back. After I stopped at the off ramp, and started driving again I noticed I had basically no power whatsoever, and there was a grinding noise that sounded like it was coming from around where the turbo is. Kind of a grududududuh sound, like something was rubbing or sticking, then suddenly it would stop and all the power would hit at once. This repeated several times on the way back, even causing me to nearly stall the car when pulling away from a stop light, then suddenly all the power shot to the wheels instantaneously and chirped 'em real loud! The car went back into limp mode on the way back to the house, and I have no idea why. Well... I have one idea why, and I don't like it.

Is it time to open up my turbo and clean the vanes?

Almost forgot to mention, now when driving at low speed it sometimes sounds like the turbo spools down a little bit, then suddenly shoots back up, then slows down a bit and back up even though I'm not changing any throttle input

EDIT: I think I've solved it, knock on wood! I was getting frustrated at the MAF code it threw earlier, so I grabbed my old detritus-caked MAF that was in the car previously and applied MAF cleaner quite liberally. I let it dry, and put the old MAF back in, to get a new code.. P0101. This only frustrated me further. I poured isopropyl alcohol onto the connector, then repeatedly plugged it in, and unplugged it to try and clean both the pins for the connector on the MAF, and the connector itself. After a bit of this, turning the car back on and going for a drive, I didn't get rev limited, nor any of the weird boost surging from before. I did a pull on a freeway on-ramp, no limp mode... I did 4 or 5 separate pulls on flat ground on an empty street, no limp mode, and I took it around town to run some errands and it also seems fine. It's always the weirdest things with Volkswagens, I swear...
 
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Tdijarhead

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2003 TDI Jetta Daughters Car, 2001 TDI Beetle, Wife’s car, 2005 Golf TDI Mine, all 5 spds
My daughter had some issues with the MAF on her Jetta a couple of months ago. After playing around with limp mode on and off for a month or so and switching out the MAF I finally replaced the connector plug itself and she hasn’t complained about low power since.
 

StrayBassist

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Sacramento, California
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98 New Beetle ALH
My daughter had some issues with the MAF on her Jetta a couple of months ago. After playing around with limp mode on and off for a month or so and switching out the MAF I finally replaced the connector plug itself and she hasn’t complained about low power since.
If I have any further issues with it, I'll replace the connector itself. I was considering doing that anyways. As is.. seems to be good, knock on wood!
 

StrayBassist

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98 New Beetle ALH
UUUUGHHH I'M STARTING TO LOSE MY GOD DAMN MIND

*ahem*


I apologize. It's acting up a bit again. Occasional low power, and back to getting abysmal fuel economy (about a quarter tank in 100 miles, took a trip to an arcade out of town and back) I've ordered a new MAF connector because.. literally what else can it be... Only once did I actually get rev limited and go into proper limp mode on the highway. Mostly I've just been guzzling diesel and being a bit down on power.
 

Tdijarhead

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The connector I bought had an extra wire (aftermarket) so be aware if your new one does be sure to line up those wires correctly. Leave the extra hanging or cut it off if yours has more than needed.
 

StrayBassist

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98 New Beetle ALH
The connector I bought had an extra wire (aftermarket) so be aware if your new one does be sure to line up those wires correctly. Leave the extra hanging or cut it off if yours has more than needed.
Duly noted. I noticed the stock one on my car has an empty spot for an extra wire and pin, so it wouldn't surprise me that some other VAG engines use the same connector with an extra pin or something. Looking closer at the inside of my connector, it looks like some of the red plastic inside of it around the pins has cracked with age, so I'm willing to bet it's not seating properly, or wiggling out from the engine vibrations over time.
 

P2B

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StrayBassist

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98 New Beetle ALH
Well, my connector came in a few days ago and a simple splice/crimp job later.. I haven't gone into limp mode once, and I've been getting about 55-60 MPG once again! (knock on wood) It seems a *little* down on power, just a tiny bit, maybe? I think I'm just being paranoid. Hopefully this is all she needs. Thanks to everyone here who helped me get through this nightmarish diagnosis lol.
 

StrayBassist

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98 New Beetle ALH
Alas, since then, I went back into limp mode and my fuel economy tanked again. Since the MAF ingested so much junk from the PO's neglect, I figured it was pretty suspect and tried changing it again after doing the other repairs. It did make a big improvement, but it isn't quite perfect. I've gone into limp mode again, once, though I'm not going into limp mode every time I rev the engine out to burn up any soot in the turbo! My coolant reservoir cap broke on me the day before I replaced the MAF, the little plug part separating from the handle part of the cap. I made sure no plastic bits fell into the reservoir and did my best to ensure the handle part is screwed on firmly and the plug is seated in there, but the car has been randomly throwing a coolant temp sensor code which generic guides seem to suggest can effect power and fuel economy..

I've been working on this damnable limp mode mystery for a month now! I've certainly spent more than just buying a VAGCOM scanner would've cost me, but the problem is I only have small amounts of money at a time and my mechanical troubleshooting fills me with enough confidence to pull the trigger on a part...

I think I'm gonna see if I can borrow some funds from a family member and just get a VCDS scanner to try to investigate better.. I'll need one eventually anyways.

What else can I go through? I don't have and can't afford a vacuum pump, and my vacuum tester is a bit basic, being this one from Harbor Freight, so I unfortunately can't really test the vacuum while driving the car, since I couldn't see the gauge when it's sitting in the engine bay, lol...

It threw a P1550 code once before I replaced the MAF and never again since, I figured it was a fluke since I replaced the N75 and tested the lines, and saw the actuator move with vacuum applied to it (albeit in a rather creative way)

Every time I get rev limited and see my fuel gauge start going down quicker, I just kind of sigh and go "of course..." at this point. Diagnosis is my least favorite part of working on these things...
 

burpod

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cape cod, ma
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82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
driving blind without vcds and being able to take logs... chances are, with vcds, this would/could have been solved in <20 min ;) .. or at least very good chance.

if money is that tight, get a $15 kkl cable at least so you can take logs check fault codes... although genuine vcds is sooooo worth it
 

StrayBassist

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Sacramento, California
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98 New Beetle ALH
Alright, I might be able to get my hands on a VCDS-Lite cable. What should I check?

Right now I have P0101 and P1256, the car seems to "surge" as I'm driving it, like the turbo doesn't kick in until out of nowhere it does, then it goes off and back on again over and over, until the car just goes into limp mode.
 
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Brett San Diego

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San Diego
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02 Jetta wagon manual
You've had a suite of open circuit codes for engine management components, and they seem to be intermittent. In my opinion, thoughts of a failing ECU should start creeping into your mind.

You may still separately have an overboost issue due to a dirty turbo causing your limp mode when you get on boost at highway speeds.

I have a spare immo-deleted ECU that I'd gladly send to you for testing, but it's for 2002-2003.

Brett
 

StrayBassist

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Sacramento, California
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98 New Beetle ALH
You've had a suite of open circuit codes for engine management components, and they seem to be intermittent. In my opinion, thoughts of a failing ECU should start creeping into your mind.

You may still separately have an overboost issue due to a dirty turbo causing your limp mode when you get on boost at highway speeds.

I have a spare immo-deleted ECU that I'd gladly send to you for testing, but it's for 2002-2003.

Brett
Y'know, I had never actually considered that. Is there any way I can test the ECU specifically? I figured if something like that was happening I'd start seeing other electrical gremlins appear, but I suppose not. I thought I'd heard the 2000-2003 ECUs could be retrofitted on the earlier ALH cars, but that may have been hogwash and poppycock.

I'm not completely ruling out a dirty turbo, as the previous owners may have babied the car but its maintenance was taken care of by a TDI enthusiast, so I feel like they would have kept any soot buildup in mind in their driving style. Before I started getting these limp mode issues I made sure to rev it out in 3rd-4th and from 4th-5th on highway on-ramps to help bring up the EGTs enough to burn that stuff off, then drive normally afterwards to let things cool back down without it going into limp mode..

AFAIK, I will need an official Ross-Tech cable to delete the immobilizer, and that's necessary to replace the ECU..

EDIT: I can't even seem to find any ECUs for sale anywhere, nor can I find consistent info on which one I'd need (what part number, if I need one specific to my manual transmission or not, if I can use a later one, etc) and there's no diesel cars at any junkyards near me right now. The only one for sale I found had part number 06A 906 018 EQ which states it's for 98-05 cars and seems to relate to an air conditioning component for an Audi..
 
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Brett San Diego

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02 Jetta wagon manual
You can delete the immobilizer yourself pretty easily using the kw1281test software and a cable from Amazon for $25. Links in this thread:


If I recall correctly, the part # of pre-2002 ALH ECU's will end with BD. 2002 is FD, and 2003 is GN. I don't know if BD is all years 1998-2001. You'll have to check your own ECU, and do some research.

I understand that the difference between pre-2002 and 2002-2003 is the glow plug wiring. Pre-2002 being 1- or 2-wire (can't remember), and 2002-03 being 4-wire. It may be possible to put in a later generation ECU just by running the appropriate wiring harness for the glow plugs. I don't know anything about it.

I'm not saying I think it is your ECU, but just be aware that it could be once you've verified to your satisfaction that all the engine management components are functioning correctly, and you're out of ideas of what to check. If you can get your hands on an immo-deleted ECU, it's very easy to just swap it in and see if it fixes everything.

The ECU is not specific for automatic or manual. That part is actually soft-coded in the ECU, and you can change it with VCDS.

I looked around SoCal LKQ yards. There is an early Beetle TDI at the San Bernadino yard and a 2001 Jetta at Victorville. They will pull parts for you, but I don't know if they will pull and ship something.

Brett
 
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StrayBassist

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Sacramento, California
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98 New Beetle ALH
Alright, sweet, thank you. I'll actually be rather serendipitously gifted a VCDS scanner soon; should get here in a few days. I might end up calling those yards; I couldn't find any early ALH cars at any of the junk yards up here in NorCal, let alone a beetle.

I'm not certain I could get an ECU easily as the typical places I'd check (junkyards, IDParts, Rockauto, VW dealerships) don't seem to have one but I'll get the part number for mine and search better, as well as checking car-part.com as Bob suggests. I wonder if I connect a Vagcom scanner and end up seeing some bizarre nonsense pointing towards it failing...

I've been considering ordering a tune from KermaTDI for some time anyways, for the earlier cars they send you a chipped and socketed ECU and charge a core deposit to send your old one back; maybe that's the route I'd take if signs point to it being the issue and I can't find one.
 
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